RESOLVING VIBRATION ISSUES OF DIESEL ENGINE

DRIVEN FIRE WATER PUMPS

Case Study
By

Sherief Mekawey
Principal MDS Engineer
GE-Bently Nevada

Contents
Background
Technical Data and Acceptance Criteria
Contractual Vibration Points
Vibration Measurement Locations at Field
Analysis
Conclusions from Investigation
Proposed Actions
Final Vibration Results
Lessons Learnt
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Background
Four numbers of Fire Water Pumps supplied newly failed to
pass SAT in 2006 due to high vibration on the Pump Head.
2 vibration consultants were involved to solve the problems
without success.
3rd vibration consultant (GE) was involved in Oct 2009,
implementation of recommendations started in 2010, hand
over in 2012.

Technical Data and Acceptance Criteria

Pump:
Vertically suspended centrifugal
pump, 3 stages
1750 rpm, water lubricated, 880
cu.m/hr

Acceptance Criteria:
As per NFPA 20 article 7.6.1.5
which refers to Hydraulic Institute
Standard (5.84 mm/s rms) at
Pump Head

Drive Shaft :
Double Universal Joint Cardan Shaft
Gearbox:
750 HP, 1750 RPM,
1:1 Ratio, Right Angle
Threaded Coupling Type
Diesel Engine:
12 Cylinders, DITA, 800HP, 1750
RPM

Contractual Vibration Points

Vibration Measurement Locations at Field

Analysis
Pump A

Comparison of vibration
signatures of Pumps A,
B & D on the GB output
Vertical location

Pump B

Observation#1:Vibration
signature
on
Gearbox
indicated that a significant
energy components getting
transmitted from the Diesel
Engine at 1X, 3X, 3.5X and
6X

Similar vib signature as recorded on

diesel engine

Pump D

Reason could be: vibration isolators are not installed either under
the engine feet nor under the frame on which the engine is
mounted.

Foundation/supporting arrangement for Diesel Engine, Gearbox and Pump.

Observation#2: Startup/coast down waterfall indicated resonance

in the speed range 1200 to 1400 rpm

Critical speed in the range of 12001400rpm

Pump-A

Pump-B

Observation#3: Bump test

data on the Gearbox
structure
indicated
a
resonance at 22.5Hz and
33 Hz, which is less than
20% separation margin
(Pump Running speed
28.75cps)

Pump-D

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Pump-A

Pump-B

Observation#4:
High
frequency spectrum on
GB indicated 1X GMF
with sidebands, possibly
due to wear of gear
teeth/excessive
backlash.

Pump-D

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Conclusions from Investigation

Unbalance of Gearbox cordon shaft or coupling hub
mounted at gearbox input shaft
Transfer of vibrations from diesel engine to the gearbox
and pump assembly
Structural resonances from gearbox support assembly.
Premature wear of gear teeth / excessive backlash.

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Proposed Actions
In situ balancing of gearbox cordon shaft and GB O/P
shaft.
Installation of vibration isolators below the engine feet or
the base frame
Modify the Gearbox structure to shift the natural
frequency with 30% separation margin.
Inspection of Gearbox for excessive gear wear/backlash.

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Actions in Sequence

Action#1: In-situ Balancing done on

GB I/P and GB O/P shafts to reduce
unbalance on cordon shaft and to
reduce excitation on the GB
structure respectively. (coupling
between Engine and GB used to
balance the GB I/P shaft. GB fan at
the top used to balance the GB O/P
shaft).

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Waterfall signature
1X component
before balancing
before balancing

Action#1 (contd): In-situ

balancing resulted in reduction of
1X. However the 22Hz
resonance component was
excited
1X component after
balancing

Waterfall signature
after balancing

Vib component at 22Hz

shown after balancing

15

Action#2: The engine stand was replaced with a new stand with vibration isolators

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Comparison of vibration spectrum before and after the modification of

engine base frame with vibration isolators

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Action#3: Pump Head structure modified

Old Pump head

New Pump head

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GB TOP

Bump test on the GB and pump head (with

modified head) showed natural frequency at
41.25 Hz (achieved 41% separation margin)
GB Bottom

Pump head

19

Action#4: Gearbox inspected and found only 70% teeth contact. GB OEM
brought to site, gear backlash was checked and adjusted to conform to OEM
specifications

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Comparison of vibration spectrum before and after the backlash adjustment

on the Gearbox
Before

High frequency GMF

components & side bands

Now

Drastic reduction of High frequency GMF

components & side bands

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Final Vibration Results

Pump-D selected as pilot, implemented all the mentioned action items and resulted in
great improvement. Red highlighted in table below is the contract specified location
(Limit 5.84 mm/s rms)

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Lessons Learned
All contractual limits must be carefully acknowledged
during design and verified during FAT.
Solving the problems in factory is much easier than
doing it on site.
Get the right consultant involved at the first chance.
Understand the size of problem since beginning could
save time, cost and efforts.
Major modifications might be a solution whenever the
problem is complex.

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END OF THE CASE

QUESTIONS?

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